STEAM TO ELECTRICITY

K.KRISHNAMOORTHY
AEE/TECHNICAL SERVICES
MTPS

IS / ISO 9001:2008
CERTIFIED POWER PLANT
Unit 1: 227days
Unit 2: 205days
Unit3: 272days
Unit4: 311days
Station: 71days

IS / ISO 9001:2008
Quality Policy:
-Uninterrupted quality power to TNEB grid
-Minimizing forced & planned outages
-Quality excellence in all our activities
Quality Objective:
-Annual generation:>6500mu
-Plant load factor :>88%
-Aux. power consumption:>8.5%
-Specific oil consumption :<1.25ml

THERMAL GENERATION
Fuel is fired in
Boiler and
Super heated
steam
Is produced

Energy in SH
Steam from
Boiler is used
for achieving
Rotational energy
In the Turbine.

Generator
connected with
Turbine rotates
and produces
Electricity.

Auxiliary
Utility
(6.6KV & 415V)
Voltage is stepped up
Connected to Grid
(110, 230, 400 & 785KV)

3/9/15

What is Turbine?
Turbine is the prime mover for the
Generator
It is a rotating machine.
Thermal energy is converted into
rotational energy by means of blades
of Impulse and Reaction.
This rotational energy is used in
Generator to generate power
LMW- Leningrade machine works,
Russian deign,supplied by BHEL

CONDENSER VACUUM
Steam from
FSH 130 ksc

1 ksc

CRH 26 ksc
Re heater

IPT

HPT

Generator

LPT

HRH 24 ksc
Condenser
Vacuum- 670mm Hg

TURBINE

HP TURBINE

IP TURBINE

LP TURBINES

HIGH PRESSURE TURBINE

Impulse Reaction Turbine

No of stages :12(1+11)
Shaft out put:65MW
Inlet/outlet Steam flow :630/590 t/hr
Inlet/outlet Steam temp : 535/330
deg
Inlet/outlet Steam pr. : 130/26 ksc

HP ROTOR &
CASING

INTERMEDIATE PRESSURE
TURBINE

Reaction Turbine
No of stages :11
Shaft out put:105MW
Inlet/outlet Steam flow :540/461 t/hr
Inlet/outlet Steam temp : 535/190
deg
Inlet/outlet Steam pr. : 24/1.32 ksc

LOW PRESSURE TURBINE

No of stages :8(4+4)
Shaft out put:40MW
Inlet/outlet Steam flow :461/446 t/hr
Inlet/outlet Steam temp : 190/45 deg
Inlet/outlet Steam pr. : 1.32/0.06 ksc

The Main Equipments of Turbine

1. Main Turbine.
2. Oil system.
3. Condenser
4. Cooling water system.
5. Hot well & Condensate system
6. HP Heaters & LP Heaters
7. Feed Water system

OIL SYSTEM
Supplies oil for lubricating all
bearings in TG set(1ksc)
Supplies oil for governing
system(20ksc)
Generator seal oil system(10ksc)

COOLING WATER SYSTEM

The clarified water used for
condenser cooling and other coolers
such as TLOC, seal oil cooler, stator
water cooler, hydrogen gas cooler.
To condense the LPT exhaust steam
in the condenser and to create
vacuum in it.

COMPRESED AIR SYSTEM

Instrument Air: operation of
pneumatic valves, BFP scoop, burner
tilt, SADC, PA fan inlet damper
operation, generator slip ring
cleaning
Service Air: Air pre heater air motor,
LDO atomization, sky climber.

AIR EVACUATION SYSTEM

Creates a vacuum in the condenser
before the steam admission,
evacuate air and non condensable
gases during normal operation
Starting Ejector: used to create
vacuum during starting
Main Ejector: Extracts non
condensing gases from condenser
and Regenerative heaters

HP LP B/P SYSTEM(30%)
During startup of the unit, to raise
the steam parameters and to match
it with Turbine parameters.
Bypass system is required to bypass
the steam w/o entering the HPT from
MSL to CRH and IPT from HRH to
Condenser.

CONDENSATE SYSYEM
The steam from the exhaust of the
LPT, condenses into water and hence
it is called as condensate
Condensate water collected in the
hotwell, at the bottom of the
condenser
CEP, Main Ejector, GSC1, LPH1,
GSC2, LPH2,3,4 and Deaerator.

DEAERATOR
Removes dissolved oxygen, from
condensate water.
To prevent internal corrosion of boiler
tubes.

FEED WATER SYSTEM

Feed water stored in the feed water
storage tank (located at the bottom
of the deaerator) is pumped th BFP,
to boiler drum th HPH5,6 7
economiser.
Re generative heaters: steam
extracted from the Turbine is used to
heat the feed water, flows th the
spirals tube of the heaters

HEAT TRANSFER
1. CONDUCTION
2. RADIATION
3. CONVECTION

CONDUCTION
CONDUCTION IS THE TRANSFER
OF HEAT FROM ONE PART OF THE
MATERIAL TO ANOTHER OR ONE
MATERIAL TO ANOTHER WHICH
ARE IN CONTACT.

RADIATION
THE TRANSFER OF HEAT FROM
THE HOT BODY TO THE COLD ONE
BY MEANS OF ELECTROMAGNETIC
HEAT WAVES OR RAYS WITHOUT
HEATING THE MEDIUM THROUGH
WHICH IT PASSES BETWEEN THE
TWO BODIES INVOLVED.

CONVECTION
HEAT TRAVELS FROM ONE
PARTICLE OF THE BODY TO
ANOTHER PARTICLE BY ACTUAL
MOTION OF HEATED PARTICLES
DUE TO DIFFERENCE IN DENSITY.

TURBINE PROTECTIONS
1. CONDENSER VACUUM VERY
LOW
2. LUBE OIL PRESSURE VERY
LOW
3. AXIAL SHIFT HIGH
4. GENERATOR TO TURBINE THRO
86T
5. BOILER TO TURBINE THRO
MFT

GENERATOR
Voltage: 15.75 KV
Capacity: 210MW
Coolant:
ROTOR- Hydrogen gas
STATOR-DM WATER

GENERATOR DESCRIPTION : T H W 210 2

T

TURBO GENERATOR

H
ROTOR

H2 COOLED STATOR &

WATER COOLED STATOR

210

ACTIVE POWER

211

POLE

Capacity
MVA)
Stator Voltage
Stator Current
Rotor Voltage

: 210 MW (247
: 15.75 KV
: 9050 Amps.
:310 Volts.

STATOR & ROTOR

Magnetic flux produced by a rotating
magnetic field passes across the air gap
and through the stator core to generate
three phase voltage in the stationary
armature winding, also called the stator
winding.
The rotating magnetic field is
created by passing current through the
rotating field winding, also called the
rotor field winding.

SEAL OIL SYSTEM

In order to prevent the escape of

Hydrogen from the turbo-generator, it is
essential to provide shaft seals at both
end where the shaft extends through
casing.
This is achieved by providing radial
and axial oil films in the system
Supply of seal oil to shaft seal :
During the operating condition of
the turbo-generator, the oil supply is
taken from the governing system at 20
Kg/cm2 pressure. After APRV seal oil
pressure is of 10-13 KSC. It is
continuously supplied

A.C & D.C Seal oil pumps :

In case of failure of governing oil or during a
stand still condition of the generator, the oil is
supplied to the seals by means of A.C. or D.C.
pumps. The stand by pump is A.C operated and
emergency pump is D.C. operated. These pumps
are electrically inter locked.

The standby A.C. pump automatically starts

in case the oil pressure (after filter) drops to 6.5
KSC and D.C. emergency pump auto start will be
initiated at a seal oil pressure of 5.5 KSC.

Reasons for generator

heating up
1. IR losses in stator/rotor

coil(copper losses)
2. Iron losses in core ( Hysteresis /
Eddy current losses)
3. Load on Rotor by the way of
excitation power (DC V & I due to
VAR loading on Generators)
4.Other frictional loss in bearings
(which are negligible)
50

Reactive Power
Inductors oppose the change in current by
dropping voltage directly proportional to rate of
change of current
Inductive Load in the power system will produce
the energy which transfers power to source
Energy, which returns to the source in each
cycle, is known as reactive power.
The loss of power in a system arising from the
production of electric and magnetic fields. This
the portion of power flow due to stored

or phantom power is called

Reactive power.
It is measured in VAR. (Volt-Amps-

51

Reactive power(cont)
KW is the real power that actually does the
work,
KVAR is the reactive power.
KVA is the apparent power
KVA is the vector sum of both the reactive(KVAR)
and the active power ( K.W.).
Mathematically, power factor is the ratio between
KW and KVA (PF = KW / KVA).
In an inductive load, such as a motor, active
power performs the work, and reactive power
creates the electromagnetic field
Power factor measures how efficiently the current
is being converted into useful real workwith a
low power factor, more electrical current will be
required to provide the same amount of

real power.

52

STATOR WATER SYSTEM

STATOR WATER SYSTEM

One of the efficient ways of taking away the losses
from the windings of any electrical machine is by
direct cooling using water.
The 200 MW/210 MW/235 MW Turbo Generators
employ a closed loop circulation of high quality
demineralised water through the stator windings
made of hollow and solid conductors.
The Generator is capable of delivering its rated
load only when the stator water cooling system is
functioning properly.

FUNCTIONS OF STATOR WATER

SYSTEM:
To cool down stator winding.
To supply polished DM water always
To supply dirt/dust free DM water.
To supply magnetic material free water.
To supply with adequate pressure temperature
and
flow of DM water to winding.
Draining facility if required.
To facilitate H2 gas sampling in stator water
system.
To expel gas or air in the stator water to avoid
contamination.
To makeup DM water if required.

Hydrogen cooling
system of
Turbogenerator

57

Characteristics of Hydrogen
Molecular weight
2.0156
Relative density
0.06952
Boiling point
-252 C

:
:
:

Critical temperature/pr : 239 C /13.2 kg/cm

Ignition Temperature
:
510 C
58

Hydrogen gas advantages

Hydrogen is used for cooling medium
primarily because of its superior cooling
properties & low density.
Thermal conductivity of hydrogen 7.3 times of
air. It also has higher heat transfer coefficient .
Its ability to transfer heat through forced
convection is about 75% better than air.
Density of hydrogen is approx. 1/14 of the air
at a given temperature and pressure. This
reduces the windage & frictional losses in high
speed machine like turbo-generator.
Increasing the hydrogen pressure the machine
59
improve its capacity to absorb & remove
heat .

Purity of Hydrogen
At pressure 0.035 atm. of hydrogen heat
carrying capacity is 1.
But at 2.0atm. of hydrogen heat carrying
capacity is 1.95 and there is serious
possibility of hydrogen explosion with in
the machine
To ensure the safety of operation purity
of hydrogen on the generator Casing
must be maintained as high as possible.
The purity of hydrogen should be 98%
above but should not be less than 98% .
60

The components of H
system

H cylinder bank
CO cylinder bank
Gas driers with reactivation
cabinet.
Gas panel. (not in service at
present ).
H circulation fans in the rotor @
both ends of exciter and turbine
ends
H coolers in the casing and its
cooling water pumps
61

SW system (Diagram)

62

Synchronous generator
operation &
synchronizing
procedures

What is meant by
synchronization?
In a Power Station, it is the term
used
for
the
process
of
connecting the Generator to the
Grid.

What are the requirements of

synchronization?
Matching of Machine Voltage,
Frequency and Phase angle with the
Grid parameters.

EVACUVATION OF POWER AT METTUR TPS

FEEDERS 8 Nos.
GOBI
INGUR
15.75 KV

GENERATOR

230 KV

POWER
TRANSFORMER

230 KV TUNNEL
DAM PH
SALEM 400 KV-I
SALEM 400 KV-II
METTUR AUTO SS
SINGARAPET

Circuit breakers
A circuit breaker is a switching and
current interrupting device. It
serves two basic purposes
Switching during normal
operating conditions for the
purpose of ,operation and
maintenance
Switching during abnormal
conditions such as short circuits
and interrupting fault currents.
There are several types of faults
and abnormal conditions. The fault
current can damage the
equipments if allowed to flow for
a longer duration.
Since the breaker is an fast acting

Circuit breakers
Types:
OCB
OMCB
ABCB
SF6

Isolators
Isolators are Off load devices
Isolators are used for disconnecting
the circuit under no load conditions
since it is operated under no load
condition it does not have any
making or breaking capacity
To prevent mal operation of
isolators it is interlocked with
circuit breakers and earth switches.
Isolators used in switchyards are
normally three pole isolators
Whereas in our 400KV yard the
isolators are of individual pole

UNIT TRIP SEQUENCE

When Trip initiated from Boiler, it
goes to generator th Turbine only.
When Trip initiated from Generator, it
goes to Boiler th Turbine only.
When Trip initiated from Turbine, it
goes to Boiler and Generator
simultaneously.
Generator Trip: Class A,B.

POWER GRID
A grid is a larger
interconnected network of
transmission lines linking
different generating stations
and load centers

OBJECTIVE OF GRID
Continuity of service
Economy of power
production

LOAD DESPATCH CENTER

Main LDC : Chennai
Sub LDC : Erode, Madurai.

GRID TYPES
National Grid
Regional Grid
State Grid

Frequency control in the

Grid
Frequency is controlled and
maintained in between 49.0
Hz. to 50.5 Hz. in the grid
through ABT(Availability Based
Tariff) system by scheduling
and matching the Generation
and the loads by Grid authority
in coordination with Load
dispatch centers/Generating
Stations/State Electricity

Voltage control in the

Grid
Voltage in the various points of
the Grid are maintained in
operating range by the Grid
authority in coordination with
Load dispatch
centers/Generating
Stations/State Electricity
Boards/ Power grid by varying
the MVAR generation,
switching on/off capacitor

Q&A

Thank You

and Best Wishes for a happy

long way in core engineering